Cosworth fuel system common problem. Be aware...
20-04-2009, 06:42 PM
#1
Cosworth fuel system common problem. Be aware...
When you buy and fit a Bosch 044 to a Sierra Cosworth you need to fit an adaptor to it adapt the female Bosch inlet to the cosworths fuel tank as it was designed for a male fitment pump.
Today a car came in with such an adaptor system, but instead of the single one piece item that I fit, it came in with a 2 piece one that leaked. Its only because it leaked that we had cause to put her on the ramp and take it apart...
The standard fuel tank to pump hose ID (Internal Diameter) is 15mm, so you need an adaptor with an OD (Outside Diameter) close to 15mm to ensure a tight fit of course. This one my customer has fitted is 11.9mm!! So yes, as you would expect, when connected to a 15mm ID pipe it leaks petrol on to the hot exhaust!.
But it gets better... or worse, depending on your opinion.
The ID of the fitting we supply is 12mm and this is crucial if you want the pump to supply enough volume of fuel to your engine to stop it melting. Guess what the ID of this aftermarket 2 piece one is?
8.9mm
Some pictures of mine, next to the offending item.
(No doubt it was cheaper than mine though? LOL)
Take care out there guys, these engines aren't cheap to replace when you melt them!
Today a car came in with such an adaptor system, but instead of the single one piece item that I fit, it came in with a 2 piece one that leaked. Its only because it leaked that we had cause to put her on the ramp and take it apart...
The standard fuel tank to pump hose ID (Internal Diameter) is 15mm, so you need an adaptor with an OD (Outside Diameter) close to 15mm to ensure a tight fit of course. This one my customer has fitted is 11.9mm!! So yes, as you would expect, when connected to a 15mm ID pipe it leaks petrol on to the hot exhaust!.
But it gets better... or worse, depending on your opinion.
The ID of the fitting we supply is 12mm and this is crucial if you want the pump to supply enough volume of fuel to your engine to stop it melting. Guess what the ID of this aftermarket 2 piece one is?
8.9mm
Some pictures of mine, next to the offending item.
(No doubt it was cheaper than mine though? LOL)
Take care out there guys, these engines aren't cheap to replace when you melt them!
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20-04-2009, 11:39 PM
#11
PassionFord Post Whore!!
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Kev yes that was my car ,pump and fitting kit was bought from bosch dealer,which you would think would supply correct item,cheeRS for finding that stu
cheeRS stu
cheeRS stu
21-04-2009, 05:28 PM
#13
Anyone who has been sold two piece blue and gold adaptors for 044s should really check the ID as soon as possible if running in excess of 400bhp.
22-04-2009, 10:59 AM
#21
stu, possibly statig the obvious here, but the fittings on the threaded bits seem to be different sizes, so how would they screw into what they are meant to screw into?
again, sorry for asking what might be a daft question, but i don't know what they would be fitted to, unless that is the adaprter you are talking about
cheers
again, sorry for asking what might be a daft question, but i don't know what they would be fitted to, unless that is the adaprter you are talking about
cheers
22-04-2009, 01:24 PM
#24
Team HOTHOT!
Also worth while noting that a check of the fuel lines from the pump to the injector rail is a good idea - I've seen a fair few Cosworths that have been jacked up at the front with the jack on the floorpan (just behind the jacking point) and this is where the fuel lines sit thus crushing them - this will cause you major issues aswell.
22-04-2009, 01:48 PM
#26
Stu i bought an 044 of you about 3 months ago, i take it the adapter i got with it is fine?? sorry to ask the obvious but id rather be safe than have a melted engine lol
22-04-2009, 02:44 PM
#29
Too many posts.. I need a life!!
Hi I got a 044 pump fitted with this 2 pc adaptor .... the red end to the tank is OD 15mm and ID is 12mm...so I thourght that all was ok...but then I saw that the little adaptor is only around ID 8,5mm towards the pump 
... the OD is 14,5mm (minus the thread) in the same place.....question is....will it be ok to drill it to 12mm or will it be to weak ?
... the OD is 14,5mm (minus the thread) in the same place.....question is....will it be ok to drill it to 12mm or will it be to weak ?
22-04-2009, 04:43 PM
#35
Too many posts.. I need a life!!
hmm...ok I understand....but there is no pressure on that side, right ? so it's only if I tighten it to much that it will break or ??
22-04-2009, 04:56 PM
#36
I wouldnt normally try and increase an alloy fittings ID by 50% to save a few quid but then If I had it in my hand to see then maybe I would decide it was ok in this case, but as blind internet advice, I can only advise that you dont do it. Sorry.
22-04-2009, 06:14 PM
#37
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What do you think about these pre pump filters, Stu?
http://cgi.ebay.co.uk/RS-TURBO-COSWO...3A1|240%3A1318
Will this be okay? Have you used these before?
Haven't measured the ID of the couplings, will do as soon as possible.
Have bought a new 044, this filter, and a new fuel filter, new fuel lines etc.
Don't want a little thing like a to small ID of a coupling to fuc* up the entire setup.
http://cgi.ebay.co.uk/RS-TURBO-COSWO...3A1|240%3A1318
Will this be okay? Have you used these before?
Haven't measured the ID of the couplings, will do as soon as possible.
Have bought a new 044, this filter, and a new fuel filter, new fuel lines etc.
Don't want a little thing like a to small ID of a coupling to fuc* up the entire setup.
Last edited by Norwegian Wolf; 22-04-2009 at 06:22 PM.
22-04-2009, 07:10 PM
#40
Too many posts.. I need a life!!
No pressure, but there is a lot of vibration and risk of stone impact etc. With fuel systems we take no risks.
I wouldnt normally try and increase an alloy fittings ID by 50% to save a few quid but then If I had it in my hand to see then maybe I would decide it was ok in this case, but as blind internet advice, I can only advise that you dont do it. Sorry.
I wouldnt normally try and increase an alloy fittings ID by 50% to save a few quid but then If I had it in my hand to see then maybe I would decide it was ok in this case, but as blind internet advice, I can only advise that you dont do it. Sorry.
ok ...
